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International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 3, March 2018, pp. 962 969, Article ID: IJMET_09_03_098 –Available online at http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=3 ISSN Print: 0976-6340 and ISSN Online: 0976-6359

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STRUCTURAL AND TRANSIENT THERMAL ANALYSIS OF PISTON USING ANSYS

WORKBENCH 15.0 I.V.Syeswanth

Assistant Professor, Mechanical Engineering, QIS Institute of Technology, Ongole, India

N. Mani Parasad Assistant Professor, Mechanical Engineering, QIS Institute of Technology, Ongole, India

ABSTRACT The study aims at replacing the aluminum alloy as piston material and replace

with composite materials without affecting the reliability of the component. The objective of the project is to reduce the weight of the piston so as to increase the fuel efficiency by replacing the conventional aluminum material with composites. If engine is the heart of the engine then piston is the most crucial component of the automobile. The piston is designed for a 4 stroke petrol engine using Design data book by PSG publications. The piston is modeled in CATIAV5R20 software by taking the side view of the piston and shaft command is applied to develop the piston. Composite materials are chosen as per the requirement of the piston and Structural and Transient thermal

analysis are performed to study the performance of piston and the results are compared with aluminum alloy to find out the best suitable material. Key words: Piston, CATIA V5R20, Structural Analysis, Transient Thermal Analysis

Cite this Article: I.V.Syeswanth and N. Mani Parasad, Structural and Transient Thermal Analysis of Piston Using Ansys Workbench 15.0, International Journal of

Mechanical Engineering and Technology, 9(3), 2018, pp. 962 969. –

http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=3

1. INTRODUCTION Piston is one of the most crucial components in mechanical engineering. Piston finds its wide applications in various mechanical systems like IC Engine, Pneumatic cylinders, Hydraulic cylinders etc. The present paper aims at design of piston for automobile applications. Piston is one of the crucial components in the design of IC Engine in an automobile. The function of a piston in an IC engine is to transfer the gases produced in the cylinder to the crank shaft. The

piston designed for IC Engines should possess good strength, thermal properties, and minimum weight. Weight reduction of piston increases fuel efficiency and composite

materials are the best materials for the weight reduction of piston. The main reasons why a piston gets damaged is due to wear and fatigue but more importantly the failure of the piston

I.V.Syeswanth and N. Mani Parasad


is due Mechanical and Thermal Stresses. The piston model of a four stroke petrol engine is designed in CATIAV5 R20 and Simulation software Ansys 15.0 is used to study the

performance of the piston. In Static Structural Analysis of piston a pressure is applied on the top of piston to study the deformation, Stresses. Transient Thermal analysis is performed on the piston to study the thermal effects on the piston. Three different composite which are have suitable characteristics have been identified, analyzed and compared with standard material.

Anup kumar shetty [1] discuses about use of different alloy materials as piston materials and using ANSYS software the best material for piston is chosen based on Static Structural

and Steady State Thermal Analysis. Dilip Kumar Sonar [2] discusses about the failure of piston is due to wear, fatigue load temperature but thermal stresses and mechanical stresses developed in the piston play important more important role in the damage of piston. Isam

Jasim Jaber [3] discusses about replacing the al alloy with composite materials. By using composite materials around 20-40 % weight of the piston is reduced without affecting the

reliability of the piston. Reduction of weight in the piston proved to be efficient in reducing the fuel consumption. P.Viswabharathy [4] discusses about optimizing the piston model using optistruct model in Hyper mesh. The CAD model is created using AUTOCAD software and hyper mesh is used to mesh the design. The result shows that though the weight of the piston is increased the modified design gives reduced fuel consumption and the increase in weight is well with in design consideration.

2. PROBLEM DESCRIPTION The main aim of the project is to replace the Al alloy material of the piston with composite materials to reduce the weight of the piston which decreases the consumption of fuel.

To Design the Model of the piston using PSG DATA book To check the suitability of the composite material without effecting the reliability of the

component

3. SIGN METHODOLOGY DE

Figure 1

Structural and Transient Thermal Analysis of Piston Using Ansys Workbench 15.0


4. DESIGN CALCULATION OF PISTON

4.1. ENGINE SPECIFICATION Parameter Value

Engine Type 4- Stroke Petrol Engine Bore 67mm

Stroke 62.4 mm Maximum Power 15.5 KW at 8500RPM Maximum Torque 19.12 NM at 7000 RPM

4.2. DESGINE PARAMETERS OF PISTON Parameter Value Unit

Piston length 62 mm Radial thickness 2 mm Axial thickness 2 mm

Thickness of piston head 6 mm Diameter of piston pin 19 mm

Thickness of barrel 8.5 mm Thickness of piston head 6 mm

4.3. MATERIAL SELECTION The material selection for piston is based on the criteria of weight reduction for which

composite plays a better role. Materials are chosen in such a way that the reliability of the component is not affected

Conventional Material for piston: Al alloy Composite Material for piston: Al 4032, ALSI 4340, Titanium Ti-6AL- 4V

Table 3 Properties of Al Alloy

Property Symbol Value units Young’s Modulus of Elasticity E 71000 M Pa

Poisson’s ratio µ 0.33 Density Ρ 2700 Kg/

Tensile Yield Strength 280 M pa

Table 4 Properties of Al alloy 4032




Table 5 Properties of ALSI 4340


Poisson’s ratio µ Density Ρ 7800 Kg/




Table 6 Properties of Titanium Ti-6AL-4V




5. DESIGN AND ANALYSIS OF PI STON

5.1. DESIGN OF PISTON USING CATIAV5R20 The Design of Piston as per the dimensions calculated from engine specification and designed using PSG Data book is modeled in CATIAV5R20.

The side view of profile of the piston is drawn in sketcher and revolved to get the piston designed. The model is converted into IGES format for importing into Ansys 15.0

Figure 2 Modeled diagram of piston

5.2. ANALYSIS OF PISTON The model design is imported in to ANSYS 15.0 and meshed and the mesh type is tetrahedral (10,128) elements are formed.

Figure 3 Meshing in ANSYS



5.3. STATIC STRUCTURAL ANALYSIS Structural Analysis is performed to observe the deformation and stresses absorbed by the

piston when a pressure of 3.5MPa is applied on the piston with piston pin being constrained and frictional supports are given for piston ring.

5.3.1. TRANSIENT THERMAL ANALYSIS Transient Thermal analysis is used to determine the temperatures and thermal quantities that changes over time. The loads applied in transient thermal analysis are the function of time. The temperature applied is about 10000C and temperature distribution and heat flux is noted for different element

5.4. RESULTS OF ANSYS

5.4.1. STATIC STRUCTURAL ANALYSIS

Figure 4 Deformation of AL alloy Maximum shear stress of AL alloy Figure 5

Figure 6 Von Moises stress of AL alloy Deformation of AL 4032 Figure 7

Figure 8 Maximum shear stress of AL 4032 Von mosies stress of AL 4032 Figure 9



Figure 10 Deformation of ALSiC Shear Stress of ALSiC Figure 11

Figure 12 Von Moises Stress of ALSiC Deformation of Titanium Ti-6AL-4V Figure 13

Figure 14 Maximum Shear Stress of Titanium Ti-6AL-4V

Figure 15 Von moises stress of Titanium Ti-6AL-4V



5.4.2. RESULTS OF TRANSIENT THERMAL ANALYSIS

Figure 16 Temperature distribution of Al Alloy Heat Flux of Al alloy Figure 17

Figure 18 Temperature distribution of Al4032 Heat flux of Al4032 Figure 19

Figure 20 Temperature distribution of AlSic 4340 Heat Flux of AlSic 4340 Figure 21

Figure 22 Temperature distribution of Titanium Ti-6AL-4V Figure 23 Heat flux of Titanium Ti-6AL-4V



6. RESULTS

6.1. STATIC STRUCTURAL ANALYSIS

Table 7 Static Structural Analysis

Material Deformation

(mm) Von Moises Stress

(Mpa) Shear Stress

(MPa) Al alloy 0.0064 61.99 35.79 Al 4032 0.0056 60.98 35.12

AlSic 0.0022 64.03 39.96 Titanium Ti-

6AL-4V 0.0039 61.4 35.45

6.2. THERMAL ANALYSIS

Table 8 Transient Thermal Analysis

Material Heat Flux (W/m2) Al alloy 75.15e5 Al 4032 64.74 e5 AlSic 26.26 e5

Titanium Ti-6AL-4V 8.86 e5 From the above the results it can be concluded that Al alloy can be replaced AlSiC

without effecting reliability of the component.

REFERENCES

[1] Anup Kumar Shetty, Abijeet TK, James William Machado, Shrivathsa, Design and Analysis of Piston using Aluminium Alloys, International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163, Issue 04, Volume 4 (April 2017) (SPECIAL ISSUE)

[2] G.Siva Prasad, K.Dinesh , Achari E.Dileep Kumar Goud, M.NagarajuK.Srikanth, Design and Analysis of piston of internal combustion engine on different materials using cae tool ansys, International Journal of Engineering and Techniques - Volume 2 Issue 3, May - June 2016

[3] Isam Jasim Jaber and Ajeet Kumar Rai, International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume – –

5, Issue 2, February (2014), pp. 64-73 [4] P.Viswabharathy, N.Jeyakumar, P.kannan, A.Vairamuthu, Design and Analysis of Piston

in Internal Combustion Engine Using ANSYS, International Journal of Emerging Technologies in Engineering Research (IJETER) Volume 5, Issue 3, March (2017).

[5] Imad R. Mustafa, Dr. Feirushah Salih. Comparison of Analysis of Folded Plate Structures by Simplified Bending Theory and ANSYS Program. International Journal of Civil

Engineering and Technology, 8(12), 2017, pp. 796-803. [6] Rajesh Prabha N, Edwin Raja Dhas J and Ramanan G, Finite Element Structural Analysis

of Connecting Rod of Aa7075-Tic Composite Using ANSYS, International Journal of Mechanical Engineering and Technology 8(7), 2017, pp. 1102 1110. –

structural and transient thermal analysis of ......results of ansys 5.4.1. static structural...

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